Integrated control circuitry and coil assembly for irrigation control

ABSTRACT

An integrated irrigation valve control device has a coil adapted to develop an electromagnetic flux sufficient to cause actuation of irrigation equipment. Control circuitry is electrically coupled to the coil to control the flux at the coil. A housing covers at least a portion of the coil and at least a portion of the control circuitry.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/510,111, filed Jul. 27, 2009, which is a continuation-in-part of U.S.patent application Ser. No. 11/228,413, filed Sep. 15, 2005, now U.S.Pat. No. 7,826,931, issued Nov. 2, 2010, all of which are incorporatedherein by reference in their entirety for all purposes.

This application is also related to: U.S. patent application Ser. No.12/510,118, filed Jul. 29, 2009; U.S. patent application Ser. No.14/931,106, filed Sep. 22, 2014; U.S. patent application Ser. No.12/886,471, filed Sep. 20, 2010, now U.S. Pat. No. 8,108,078, issuedJan. 31, 2012; U.S. patent application Ser. No. 13/332,337, filed Dec.20, 2011, now U.S. Pat. No. 8,793,025, issued Jul. 29, 2014; and U.S.patent application Ser. No. 14/304,502, filed Jun. 13, 2014, all ofwhich are incorporated herein by reference in their entirety for allpurposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to irrigation control devicesand more specifically to multi-wire irrigation control systems includingremote devices coupled to a multi-wire path and for coupling to actuatorcoil-controlled irrigation equipment.

2. Discussion of the Related Art

In decoder-based irrigation control systems, an irrigation controllersends signaling along a wire path to which one or more decoder devicesare attached. Each decoder device monitors transmissions on the wirepath and decodes this signaling to determine when to cause irrigationdevices coupled thereto to be activated and deactivated. The decodermodule typically includes circuitry formed on a printed circuit boardlocated within a housing. Wiring from the decoder module housing must becoupled to the wiring of the wire path as well as coupled to one or moreactuator devices each controlling the opening and closing of anirrigation rotor or valve. In one form, the rotor or valve is operatedby a solenoid coil as is well known in the art. Likewise, duringinstallation, the operator must provide and electrically connect twoseparate devices, a decoder module and an actuator coil module, to eachother and to the control wire path. FIG. 1 illustrates a separatedecoder module 102 and a coil unit 104 that are conventionally coupledtogether. For example, as illustrated in FIG. 2, for a solenoidactivated rotor assembly 200, the coil module 104 is coupled (in part bya bracket 212 and retainer 214) to the parts of a selector valveassembly 202 (including a pressure regulator) attached to a casingassembly 204. The electrical wire inputs to the coil module 104 are thenconnected to the electrical wire outputs from the decoder module 102,while the electrical wire inputs to the decoder module 102 are coupledto the control wire path from the irrigation controller. Thus, a typicalinstallation requires the connection of six wires to install the decodermodule 102 and a coil module 104.

As is well known, in operation, a portion of a plunger (not shown) ofthe selector valve assembly 202 is disposed within the coil unit 104while another portion is seated against a solenoid plunge port (notshown) within the selector valve assembly 202 in a normally closedposition. In this position, high pressure water flow from a main watercontrol valve (not shown) located within a main control valve portion206 of the device is flowed up high pressure water line 208 into theselector valve assembly 202 and its regulator and is prevented fromfurther movement by the normally closed position of the plunger againstthe solenoid port in the selector valve assembly 202. This results in aback pressure that causes the main water control valve to close. Inresponse to signals from the decoder module 102, the coil module 104causes the actuation of the plunger to move it off of (or unseat from)the solenoid plunge port allowing the high pressure flow in the highpressure line 208 to flow through the selector valve assembly 202 (andits pressure regulator), which relieves the back pressure and allowswater to flow through the main control valve and to a pop-up sprinklerdevice, i.e., the main water control valve is opened. The pop-upsprinkler device is located within the casing assembly 204 and extendsupwardly due to the water pressure through a top portion of the casingassembly 204. The high pressure flow exits the selector valve assembly202 down through a discharge flow line 210 which terminates within thecasing assembly 204 at a location downstream of the main water controlvalve.

SUMMARY OF THE INVENTION

Several embodiments of the invention provide an integrated valveactuator coil and control module for use in irrigation control systems.

In one embodiment, the invention can be characterized as an irrigationcontrol device comprising: a coil adapted to develop an electromagneticflux sufficient to cause actuation of irrigation equipment; controlcircuitry to receive a control signals from an irrigation control unitand electrically coupled to the coil to control the flux at the coil;and a housing covering at least a portion of the coil and at least aportion of the control circuitry.

In another embodiment, the invention can be characterized as a method ofmaking an irrigation control device comprising: holding a solenoidassembly with a coil near to control circuitry having circuitry forcontrolling an electromagnetic flux at the coil; electrically connectingthe coil to the control circuitry; placing the solenoid assembly andcontrol circuitry into a housing; securing the solenoid assembly to thehousing so that the solenoid assembly is actuated to reciprocate a valvemember through an aperture in the housing to selectively engage a valveseat external to the housing; and fixing the control circuitry and coilwithin the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of severalembodiments of the present invention will be more apparent from thefollowing more particular description thereof, presented in conjunctionwith the following drawings.

FIG. 1 illustrates a separate sprinkler coil and decoder module forcontrolling irrigation equipment in a conventional decoder-basedirrigation control system.

FIG. 2 illustrates a conventional decoder and electric sprinklerapplication including a separate coil module and decoder module.

FIG. 3 illustrates an integrated coil and decoder module for use in adecoder-based irrigation control system in accordance with oneembodiment of the invention.

FIG. 4 illustrates a decoder and electric sprinkler applicationincluding an integrated coil and decoder module in accordance withseveral embodiments of the invention.

FIG. 5 illustrates decoder circuitry and a coil module of the integrateddevice of FIG. 3 shown without the decoder housing in accordance withone embodiment of the invention.

FIGS. 6A and 6B illustrate other views of the integrated coil anddecoder module of FIG. 3 in accordance with other embodiments of theinvention.

FIG. 7 illustrates the decoder housing of one embodiment of the deviceof FIG. 3.

FIG. 8 illustrates a coil housing of one embodiment of the device ofFIG. 3 with a partial cutaway showing a wire coil.

FIG. 9 is a diagram of a decoder-based irrigation control systemincluding multiple integrated coil and decoder modules according toseveral embodiments of the invention.

FIG. 10 illustrates a lower side perspective view of a form of anintegrated irrigation valve control device mounted on a sprinklerassembly in accordance with one or more additional embodiments of theinvention.

FIG. 11 illustrates an exploded perspective view of one embodiment ofthe integrated irrigation valve control device of FIG. 10.

FIG. 12 illustrates a cross-sectional right side view of one embodimentof the integrated irrigation valve control device of FIG. 10.

FIG. 13 illustrates an exploded front perspective view of one embodimentof control circuitry, spacer, and solenoid coil of the integratedirrigation valve control device of FIG. 10.

FIG. 14 illustrates an exploded rear perspective view of one embodimentof control circuitry, spacer, and solenoid coil of the integratedirrigation valve control device of FIG. 10.

FIG. 15 illustrates a top plan view of one embodiment of the integratedirrigation valve control device of FIG. 10 and the components thereinbefore sealant or potting material is placed in the housing.

FIG. 16 illustrates a top plan view of one embodiment of the integratedirrigation valve control device of FIG. 10 mounted on a valve assembly.

FIG. 17 illustrates a front elevational view of one embodiment of thecontrol circuitry of the integrated irrigation valve control device ofFIG. 10.

FIG. 18 illustrates a rear elevational view of the control circuitry ofFIG. 17.

FIG. 19 is a functional block diagram of one embodiment of the controlcircuitry shown in FIGS. 17-18.

FIG. 20 is an upper and right side perspective view of the integratedirrigation valve control device of FIG. 10 prior to installation inaccordance with one embodiment.

FIG. 21 is a lower and right side perspective view of the integratedirrigation valve control device of FIG. 10 prior to installation inaccordance with one embodiment.

FIG. 22 is a fragmentary, side cross-sectional view of an alternativevalve and end structure for the integrated irrigation valve controldevice of FIG. 10.

Corresponding reference characters indicate corresponding componentsthroughout the several views of the drawings. Skilled artisans willappreciate that elements in the figures are illustrated for simplicityand clarity and have not necessarily been drawn to scale. For example,the dimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help to improve understanding of variousembodiments of the present invention. Also, common but well-understoodelements that are useful or necessary in a commercially feasibleembodiment are often not depicted in order to facilitate a lessobstructed view of these various embodiments of the present invention.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles ofexemplary embodiments. The scope of the invention should be determinedwith reference to the claims.

Referring first to FIG. 3, a perspective view is shown of an integratedcoil and decoder module 300 for use in a decoder-based irrigationcontrol system in accordance with one embodiment of the invention. Theintegrated coil and decoder module 300 includes a module body 302 (alsoreferred to simply as body 302) including a decoder housing 304 (alsoreferred to as a first housing) and a coil housing 306 (also referred toas a second housing, solenoid housing or coil unit). The module 300 alsoincludes electrical connector wires 308 and 310 (also referred to aselectrical connections 308 and 310) extending from the decoder housing304. The decoder housing 304 includes decoder circuitry (e.g., shown inFIG. 5) and the coil housing 306 includes a wire coil or solenoid (e.g.,shown in FIG. 8) formed within. Although the decoder housing 304 and thecoil housing 306 are separate functional components, they are integratedtogether to form a single integrated coil and decoder module 300.

Advantageously, since the module 300 is integrated into a single body302, an installer need only connect the two electrical connections 308and 310 to the control wire path of a decoder-based irrigation controlsystem. It is noted that any electrical connections between the decodercircuitry within the decoder housing 304 and the wire coil within thecoil housing 306 are already made and sealingly contained within thebody 302.

Referring next to FIG. 4, a perspective view is shown of a decoder andelectric sprinkler application including the integrated coil and decodermodule 300 of FIG. 3. In this embodiment, in a solenoid activated rotorassembly 400, the coil housing 306 (or solenoid housing) is coupled (inpart by the bracket 212 and the retainer 214) to the components of theselector valve assembly 202 attached to the casing assembly 204 (whichis typically buried underground or located within a valve box above orbelow ground). In the illustrated embodiment, the casing assembly 204contains a pop-up and rotary sprinkler device (not shown). Accordingly,an installation in accordance with this embodiment only involves theconnection of two wires (e.g., electrical connections 308 and 310) toinstall the decoder module 300, as opposed to six wires in the separateddecoder module and coil module as illustrated in FIG. 2. Thus, with thenew module according to several embodiments of the invention, the taskof installing a decoder module and coil unit is simplified since thereare fewer wires to connect. Additionally, this embodiment provides aspace-saving design that is more streamlined and easier to install withless clutter due to excess wires. Furthermore, the installer only needsto provide and install a single integrated device rather than purchasingand providing a separate decoder module and a separate coil housingmodule.

In operation, a portion of a plunger (not shown) of the selector valveassembly 202 is disposed within a core tube (not shown) that extendsinto the opening of the coil housing 306 about which the coil is woundwhile another portion of the plunger is seated against a solenoid plungeport (not shown) within the selector valve assembly 202 in a normallyclosed position (e.g., a spring within the core tube holds the plungeragainst the solenoid plunge port). In this position, high pressure waterflow from a main water control valve (not shown) located within a maincontrol valve portion 206 of the device is flowed up high pressure waterline 208 into the selector valve assembly 202 and its regulator and isprevented from further movement by the normally closed position of theplunger against the solenoid port in the selector valve assembly 202.This results in a back pressure that causes the main water control valveto close. In response to signals from the decoder housing 304 portion ofthe integrated coil and decoder module 300, the coil module 306generates a magnetic field that causes the actuation of the plungerwithin the core tube to move it off of (or unseat from) the solenoidplunge port allowing the high pressure flow in the high pressure line208 to flow through the selector valve assembly 202 (and its pressureregulator), which relieves the back pressure and allows water to flowthrough the main control valve and to a pop-up sprinkler device, i.e.,the main water control valve is opened. The high pressure flow exits theselector valve assembly 202 down through a discharge flow line 210 whichterminates within the casing assembly 204 at a location downstream ofthe main water control valve. It is noted that the core tube extendsthrough the bracket 212 and the opening of the coil module 306 such thata portion extends through the back opening of the coil module 306 andback side of the bracket 212. The retainer 214 is preferably a rubberend cap that is positioned over the portion of the core tube extendingtherethrough to hold the coil module 306 in position against the bracket212 and the selector valve assembly 202.

Referring next to FIG. 5, a view is shown of the decoder circuitry andcoil module of the integrated device of FIG. 3 without the decoderhousing in accordance with one embodiment of the invention. Illustratedis a printed circuit board 502 including decoder circuitry 504 formed onor otherwise coupled to or attached to the printed circuit board 502.Also illustrated are the electrical connections 308 and 310 coupled tothe decoder circuitry 504 for connection to the control wire path of thedecoder-based irrigation control system, as well as electricalconnections 506 and 508 extending from the decoder circuitry 504 intothe coil housing 306 to electrically couple the decoder circuitry 504 tothe wire coil of the coil housing 306. It is noted that the decodercircuitry 504, as well as the coil housing 306 including the coil formedwithin, are well-known in the art. For example, in one embodiment, thedecoder circuitry 504 is found within commercial decoder modulesavailable from the Rain Bird Corp., Glendora, Calif., for example, asingle channel, single coil decoder (part number FD-101). Likewise, inone embodiment, the coil housing 306 is commercially available from theRain Bird Corp., Glendora, Calif., as rotor coil, part number 212165.

In accordance with one embodiment, a commercially available coilhousing, such as coil housing 306, is electrically coupled tocommercially available decoder circuitry, such as decoder circuitry 504,via electrical connections 506 and 508. Such decoder circuitry includeselectrical input connections, such as electrical connections 308 and 310to be coupled to the control wire path of a decoder-based irrigationcontrol system. The decoder circuitry 504 and coil housing 306 are theninserted into a volume (see volume 706 of FIG. 7) formed within ahousing, such as the decoder housing 304, such that the electricalconnections 308 and 310 extend through at least one opening formed inthe decoder housing 304. Generally, a portion of the coil housing 306extends into the volume formed within the housing 304, while the portionof the coil housing 306 that is adapted to mate to the selector valveassembly 202 extends out of this volume. Next, a sealant material isfilled into the remaining volume within the housing 304 in order tohermetically seal the electronic components within the housing as wellas to hermetically and rigidly seal the coil housing 306 to the decoderhousing 304. The sealant material may comprise any suitable pottingmaterial, such as an epoxy, that is initially in a liquid or fluid stateand filled within the volume, and which hardens or cures with time. Inother embodiments, other suitable sealants may be applied to theinterface between the decoder housing 304 and the coil housing 306without filling the volume of the decoder housing. Advantageously, theresulting module 300 is an integrated single device in which the decodercircuitry and the coil housing are rigidly fixed to each other and forma single integrated body 302. This embodiment is easy to construct fromcommercially available components. However, it is noted that in otherembodiments, the coil housing 306 and the decoder housing 304 comprise asingle housing that is not required to be coupled or otherwisehermetically sealed to each other. Thus, in such embodiments, the wirecoil may be directly electrically coupled to the printed circuit board502 and the decoder circuitry 504 within the same housing. A specificexample of such a one-piece housing is illustrated in FIGS. 10-21 anddescribed in detail below.

FIG. 6A illustrates a perspective view of the integrated coil anddecoder module 300 illustrating one embodiment of connection openings602 and 604 formed in a bottom wall 704 of the decoder housing 304. Inthis embodiment, the electrical connections 308 and 310 extend throughthe openings 602 and 604 as the decoder circuitry 504 is positionedwithin the housing 304. FIG. 6B illustrates another perspective view ofthe integrated coil and decoder module 300 illustrating a sealant orpotting material 606 filling the interior volume of housing andpreventing moisture or other contaminants from entering the housing 304at the interface between the decoder housing 304 and the coil housing306 and at the openings 602 and 604. It is noted that in otherembodiments, a single opening (as opposed to the two openings 602 and604), is formed in the decoder housing 304 that any electricalconnections extend through, while a suitable sealant or potting materialseals the opening.

Referring next to FIG. 7, a perspective view is shown of the decoderhousing 304 of the device of FIG. 3. As illustrated, in preferred formthe decoder housing 304 has an elongated rectangular parallelepipedgeometry formed by side walls 702 and a bottom wall 704. A top end ofthe housing 304 is open illustrating a volume 706 formed within and forreceiving the decoder circuitry and in some embodiments, at least aportion of the coil housing 306. It is noted that the shape of thedecoder housing 304 may take many forms other than that illustrated.

Referring next to FIG. 8, a perspective view is shown of the coilhousing 306 of the device of FIG. 3 with a partial cutaway view to showthe wire coil. The coil housing 306 includes a coil portion 802 (orsolenoid portion) and a neck portion 804. In preferred form, a portionof the neck portion 804 extends into the volume 706 formed in thedecoder housing 304. However, in other embodiments, coil housing 306does not extend into the volume but nevertheless is rigidly andsealingly coupled to the decoder housing 306. The coil portion 802 ispreferably cylindrically shaped and formed about an opening 806. Thus,the coil portion 802 has an outer cylindrical periphery and an innerconcentric cylindrical periphery. The coil portion 802 contains a wirecoil 808 or solenoid (shown in the partial cutaway view of FIG. 8)wrapping about the inner periphery and sealingly contained within thewalls of the coil portion 802. As is well known in the art, the wirecoil 808 wraps about the inner periphery in a coil shape. Upon theapplication of an electrical current through the wire coil 808, anelectromagnetic flux is formed in the opening 806 of the coil portion802 about a central axis 810 extending through the opening 806. Thisflux is used to actuate a component 812 or device (such as a plunger)typically moveable along the central axis 810 (e.g., along the path ofarrow 814) within the opening 806 of the coil portion 802 in order tocause the opening or closing of a solenoid actuated irrigation valve(e.g., in one embodiment, by opening a valve of a selector valveassembly 202 controlling the solenoid actuate irrigation valve). Inpreferred form, the component 812 does not contact the inner surfaces ofthe coil portion 802 in the opening 806 and is metallic and/or magneticin order to respond to the generated electromagnetic flux. In oneexample, the component 812 is a plunger contained within a core tube(not shown) that extends through the opening 806 and is coupled to aselector valve assembly (such as selector valve assembly 202 of FIG. 4).The plunger is held in a normally closed position within the core tubeby a spring also within the core tube. Upon the application of currentto the wire coil 808, the plunger is caused to move within the core tuberelative to the coil housing 306 (and wire coil 808) and the core tubeto open the selector valve assembly as described above. One end of thecore tube extends through the opening 806 to allow a retainer (such asretainer 214) to help hold the coil module or housing 306 in positionabout the core tube and the selector valve assembly. Such coil housings306 including the wire coil 806, as well as core tube and plungerassemblies are well-known in the art.

Referring next to FIG. 9, one embodiment is shown of a decoder-basedirrigation control system 900 including several integrated coil anddecoder modules 300 according to several embodiments of the invention.An irrigation controller 902 provides a control wire path 901 extendingfrom the controller 902 into a geographic region where irrigation isdesired. The control wire path 901 is typically buried underground. Itis understood that multiple separate control wire paths may be outputfrom the controller 902; however, for purposes of illustration, only asingle control wire path 901 is shown. Typically, the control wire path901 includes two wires, a power wire 904 and a common wire 906. In otherembodiments, the control wire path 901 has three wires as is well knownin the art. Thus, the control wire path 901 may also be referred to as amulti-wire path. A power signal, e.g., 24 volts AC, from the controller902 is sent on the power line 904 to any connected devices while thecommon line provides a return to complete the circuit. Generally, thepower signal is of sufficient voltage to cause a magnetic flux in thecoil housing to open a solenoid activated valve 908. In other words, theelectromagnetic flux is sufficient to control irrigation equipment. In adecoder-based system, the power signal is modulated or encoded with datathat is readable by the decoder circuitry as is known in the art so thatthe controller 902 can control multiple irrigation valves using thesingle control wire path 901.

At various locations in the field, an integrated coil and decoder module300 according to several embodiments of the invention is directlycoupled to the control wire path 901. For example, at various locationsin the field, the electrical connections 308 and 310 are coupled to thepower line 904 and the common line 906. In one embodiment, the lines andconnections are respectively coupled together using a twist-on wireconnector and silicon grease to provide water resistant electricalconnections. The decoder portion of the integrated coil and decodermodule 300 decodes the modulated or encoded power signal on the powerline 904 and determines whether or not to provide the power signal(electrical current) to the wire coil of the integrated coil and decodermodule 300 (e.g., via electrical connections 506 and 508).

As described above, the wire coil generates a magnetic flux sufficientto cause device of an actuator or solenoid assembly 912 (e.g., in oneembodiment, to actuate a plunger of a selector valve assembly 202) toopen a normally closed solenoid operated valve 908 (e.g., in oneembodiment, a main control valve of a main control valve portion 206),which is coupled to a water supply line on one end and to one or moresprinkler devices on the other end. It is noted that in embodimentsimplemented in a solenoid activated rotor assembly for a pop-upsprinkler device, that a given integrated coil and decoder modulecouples to a solenoid operated valve 908 that couples to a singlesprinkler device; however, that in other embodiments, the solenoidactivate valve 908 may be coupled to multiple sprinkler devices. It isfurther noted that generally, a sprinkler device may be any rotordevice, stationary device, drip device, etc. As is known, there may bemultiple integrated coil and decoder modules 300 coupled to the controlwire path 901 at various locations, for example, tens or hundreds ofmodules 300 coupled to the control wire path 901. Advantageously,according to several embodiments of the invention, by providingintegrated coil and decoder modules 300 instead of separate decodermodules and coil units that must be coupled to each other and to thecontrol wire path, the installation process has been simplified byreducing the number of wires than an installer must connect and byproviding a more streamlined design at the casing assembly 204.Additionally, the decoder circuitry and the coil housing form a singlerigid and integrated body.

Referring to FIGS. 10-21, in an alternative form, in accordance with oneor more additional embodiments, an integrated irrigation valve controldevice 10 (also referred to as an integrated valve control device, avalve control device or an integrated control device) is mounted onirrigation equipment 12 such as a sprinkler assembly or a solenoidactivated rotor assembly that operates similarly to the rotor assembly400 described above. Thus, the integrated control device 10 attaches toa solenoid port or selector assembly 202 that has a solenoid valve seatas with rotor assembly 400. In this case, however, the solenoid port 202has interior threads for receiving a threaded end 24 of the integratedcontrol device 10 as described in detail below. FIGS. 20 and 21 provideperspective views of the integrated valve control device 10 prior toinstallation or mounting to the irrigation equipment 12.

In this example, integrated control device 10 has a housing 14 forcovering at least a portion of a coil 16 and at least a portion ofcontrol circuitry 18 (which may also be referred to as a devicecontroller or control electronics). In one form, the housing 14 isintegrally formed as one-piece such as by plastic molding although thehousing could be made of multiple pieces and made of other non-plasticmaterial. The coil 16 is part of a solenoid assembly 20 such as a RainBird latching solenoid and develops an electromagnetic flux sufficientto cause actuation of a valve portion of the rotor assembly 12 byopening and closing a solenoid port as described above for theirrigation module 300 and sprinkler assembly 400.

The housing 14 has an open end 22 and an opposite threaded end 24 forsecuring the housing onto the solenoid port 202 of the sprinklerassembly 12. The threaded end 24 has an aperture 26 so that a valvemember or plunger 28 of the solenoid assembly 20 can reciprocate throughthe aperture 26 to selectively engage a valve seat and open and closethe solenoid port 202 that is disposed externally to the housing 14.

The control circuitry 18 receives operational power and control signalsfrom an irrigation controller or other irrigation control unit orinterface unit coupled to an irrigation controller, as described above,and is electrically coupled to the coil 16 to control the flux at thecoil 16. In one form, the control circuitry 18 includes a circuit board32 with electronic components 34 mounted on the board. The controlcircuitry 18 also has at least one, but here two input control wires 36and 38 that may also provide operational power, similar to wires 308 and310. In other embodiments with a three wire control path, there arethree control wires. The wires 36 and 38 extend from the board 32 andout of the open end 22 of the housing 14 for connection to a controlwire path of the irrigation control unit or system. In this form then,the input control connection 40 where the circuit board 32 connects tothe wires 36 and 38 remains within the housing 14. This may be true nomatter the form of the input transmitter whether by more or less wiresthan wires 36 and 38, or whether by wireless receiver or other inputdevice connected to the circuit board 32. Thus, in the illustratedexample, the only parts extending out of the housing 14 are the twowires 36 and 38, and the plunger 28. Otherwise, the housing 14 is sizedto cover the entire circuit board 32 and the entire coil 16.

It will be appreciated, however, that a housing may be provided to coveronly parts of both structures such that either a portion of the coil ora portion of the control circuitry extends out of the housing whenaccess to either portion is a priority, for example. In either case, inthe illustrated example, any electrical connection between the coil 16and the control circuitry 18 remains within housing 14 as described ingreater detail below. Thus, this configuration eliminates the time andcost of labor for connecting a solenoid coil to the control circuitry inthe field for potentially hundreds of sprinkler assemblies at a singleirrigation system site.

In one form, the solenoid assembly 20 with the coil 16 and the controlcircuitry 18 are initially placed within housing 14 without anyseparation structure between them. Once placed, the housing 14 is filledwith a curable, non-conductive potting material 52, including betweenthe control circuitry 18 and the coil 16, that hardens to rigidly holdthe control circuitry 18 spaced from the coil 16 to reduce the chancesof a short circuit.

In the illustrated alternative embodiment, however, the integrated valvecontrol device 10 also has a spacer 50 disposed between the controlcircuitry 18 and the coil 16 to maintain the coil at a predeterminedposition relative to the control circuitry 18. Specifically, the spacer50 is positioned to prevent a short circuit caused by the coil 16 ormetal components on the solenoid assembly 20 coming into contact withthe electronics on the circuit board 32. Thus, the spacer 50 at leastmaintains the coil 16 spaced from the circuit board 32. The coil 16 maysit loosely on the spacer 50 until a curable, insulating sealant orpotting material 52 is poured into the housing 14 and solidifies theposition of each of the components within the housing. The spacer 50also is made of a non-electrically conductive material such as plasticto further insulate the coil 16 from the circuit board 32. As explainedbelow, the spacer 50 also may be used to secure the coil 16 relative tothe circuit board 32 in at least one other direction (e.g.,longitudinally, laterally).

In more detail, the solenoid assembly 20 includes a bobbin 42 supportingthe coil 16. The bobbin 42 has an annular core 44 and two flanges 46 and48 extending radially outward from the core 44 with the coil 16 mountedbetween the flanges. The flanges also extend radially outward past thecoil 16. A metal, U-shaped bracket or yoke 54 extends around the bobbinand has a lower flange or end 60 and an upper flange or end 61 (hereinthe words upper and lower are used merely to describe internal relationof parts and do not necessarily reflect an orientation of the device10). The upper end abuts a raised portion 47 of the upper flange 46 ofthe bobbin 42. An annular magnet 56 and washer 58 are attached to thelower end 60 of the bracket 54.

A core tube 62 is inserted through the aperture 26, the bobbin 42, andthe bracket 54. The core tube 62 has a widened end 64 that extendsradially over a ledge 66 formed within aperture 26 so that the ledge 66retains the widened end 64 in the aperture 26. An opposite end 68 of thecore tube 62 extends through the bracket 54 to be engaged with a jam nut70 above the bracket 54. An O-ring 72 is disposed between the ledge 66and the widened end 64. With this configuration, the solenoid assemblyis secured to the housing 14 by tightening the jam nut 70.

The widened end 64 of the core tube 62 has a cavity 74 for looselyreceiving the plunger 28. The plunger 28 is metal so that the magnet 56maintains the plunger in the core tube 62. By applying a pulse of fluxto the coil 16, the plunger may be moved to an open or closed position.A biasing member or spring 76 mounted on the plunger 28 compressesagainst the core tube 62 while the plunger 28 is in a retracted openposition (away from an external valve seat and solenoid port). Thisreduces the force necessary to advance the plunger 28 to the closedposition where the plunger 28 extends out of, or extends farther out of,the end 24 of the housing 14 for engagement with the external valveseat.

In the illustrated form, all of the parts of the solenoid assembly 20mentioned above except for the plunger 28 are maintained within thehousing 14. It will be understood, however, that many variations arecontemplated where some of the parts mentioned may be placed or extendexternally of the housing 14, such as core tube 62.

Referring to FIG. 22, instead, other external parts of the irrigationequipment may be placed within the housing 14 as part of the integratedcontrol device 10, such as the solenoid port and valve seat that theplunger engages. For example, an alternative valve end structure 160 maybe placed within an end cavity 162 formed on threaded end 24 inaccordance with another embodiment. Such an end structure 160 includes avalve seat member 164 with a discharge fluid passage 166 with an opening174 that is closed by axial engagement with the plunger 28. A filter 168is placed around the exterior of the valve seat member 164 to filterfluid flowing to a side inlet passage 170 formed on the valve seatmember 164. In the example form, the filter 168 may be snap-fit orotherwise secured to the threaded end 24 to hold the valve seat member164 in place on the housing 14. With this structure, fluid flows throughthe inlet fluid passage 170, into aperture 26, and is either blocked orpermitted to flow out the discharge fluid passage 166 depending onwhether the plunger 28 covers the opening 174 to the discharge fluidpassage 166.

Referring to FIGS. 12-14, the spacer 50 has a main, generally flatmember 78 that is aligned with the coil 16. Specifically, the mainmember 78 has a first side 80 facing the coil and that is curvedgenerally about a longitudinal axis L of the coil 16 to match thecylindrical, outer surface or curvature 82 of the coil 16. In theillustrated form, the entire member 78 is curved rather than just thefirst side 80. So shaped, first side 80 forms a recess 83 for receivingthe coil 16. The first side 80 extends around the coil 60 sufficient tolimit motion of the coil 16 relative to the spacer 50 and circuit board32 in a lateral direction (perpendicular to the axis L and parallel to aplane P generally defined by the circuit board 32).

The main member 78 also includes an outer frame portion 84 and aprojecting portion 86 that, in one example, spans the frame portion 84and projects radially inward from the frame 84 to extend directlybetween the flanges 46 and 48 of the bobbin 42. The projecting portion86 has a longitudinal height that approximately matches the distancebetween the flanges 46 and 48 to retain the solenoid assembly, relativeto the spacer 50 and circuit board 32, in a longitudinal direction(parallel to the axis L of the coil 16) and parallel to the plane P ofthe circuit board 32.

The main member 78 also has a flat surface 88 to engage a flat surface90 on the bobbin 42 to limit rotation of the solenoid assembly 20 andcoil 16 relative to the spacer 50 and circuit board 32. In oneembodiment, the flat surface 88 is formed on a plate portion 79 spanningfrom the projecting portion 86 to the frame portion 84.

The spacer 50 also has at least one stand, here two upper stands 92 anda lower stand 94 extending toward the circuit board 32 from a secondside 95 of the main member 86 opposite the first side 80. Two laterallyspaced stands 92 extend from an upper part of the frame portion 84 andhave a flat surface 96 elongate in a longitudinal direction for lyingflush on the circuit board 32. The stand 94 extends from a lower part ofthe frame portion 84 and has a plus-shaped flat surface 98 forcontacting the circuit board 32. These stands 92 and 94 assist inmaintaining at least some distance between the coil 16 and the circuitboard 32, and since the second side 95 of the main member 78 is convex,the stands 92 and 94 also limit rolling of the spacer 50 relative to thecircuit board 32.

Pins 97 also extend from the second side 95 of the spacer 50 forinsertion into holes 99 on the circuit board 32 to secure the spacer 50,and in turn the coil 16, laterally and longitudinally (or all directionsparallel to the plane P) relative to the circuit board 32.

As mentioned above, once the control circuitry 18, spacer 50, and coil16 are disposed within the housing 16, the housing is filled with thepotting material 52 at least between the control circuitry 18 and thecoil 16. In one form the potting material 52 fills a sufficient amountof the housing 16 to substantially hold the components in fixedpositions relative to each other and within the housing 16, and can evenbe described as fixing the components to each other. For example, in theillustrated form, the coil 16 is loosely placed against the spacer 50.Thus, while the main member 78 may secure the coil 16 laterally,longitudinally, and rotationally relative to the spacer 50, the coil 16can easily be moved laterally away (in a direction perpendicular toplane P) from the spacer 50 and circuit board 32. however, once thepotting material 52 fills the voids around the coil 16 and spacer 50,the coil 16 will also be substantially secured to the spacer 50 in atleast one direction, and here laterally toward the circuit board 32 andspacer 50. To permit the potting material 52 access to the voids aroundthe spacer 50, the spacer 50 has at least one through hole 110 toreceive the potting material 52 so that a bridge of potting material canextend from the first side 80 to the second side 95 of the main member78. The ends 112 and 114 of the coil 16 may also extend through thethrough-holes 110 to connect to the circuit board 32 at connections 118.

With this configuration, the control circuitry 18 and solenoid assembly20 and/or coil 16 occupy the same volume such that, at least along theside of the coil facing the control circuitry 18 or circuit board 32,only the spacer 50 and potting material 52 are placed directly betweenthe control circuitry 18 and the coil 16. It will be understood that theterm coil here includes any tape or wrapping that remains around thecoil to holds the coil wires in place.

In some embodiments, the potting material 52 has a coefficient ofthermal expansion such that the electronic components 34 on the circuitboard 32 are not substantially affected by the expansion and contractionof the potting material 52 as temperature changes. The potting material52 will also seal the housing from moisture and other contaminants asmentioned above. One example of such a potting material is a two-partepoxy made by Epoxy Formulations, Inc.

Referring to FIG. 12, the housing 14 is made as small as possible toreduce the likelihood of damaging the integrated control device 10 andto make the integrated control device 10 more adaptable for attachmentto a variety of irrigation equipment. More specifically, in order tomake the height (or longitudinal length parallel to axis L) of thehousing 14 as short as possible, the control circuitry 18, or morespecifically the circuit board 32, is placed along a side 116 of thecoil 16 so that the longitudinal lengths of the coil 16 and controlcircuitry 18, and spacer 50 if present, all overlap. In one form, thecircuit board 32 is approximately the same longitudinal length as thespacer 50, and the total longitudinal length of the circuit board 32 isno more than approximately twice the longitudinal length of the coil 16.A shorter housing will reduce the chances that the integrated controldevice 10 is unintentionally impacted by a shovel while the irrigationdevice upon which it is attached is placed into or dug up from theground. The reduced size will also reduce compaction and expansionstresses caused by freeze/thaw cycles in cold weather climates.

Optionally, it will be understood that while the circuit board 32 isplaced along a side 116 of the coil 16 so that the circuit board 32extends parallel to axis L of the coil, the circuit board 32 couldalternatively be placed to extend transverse to axis L over the upperend 61 of the bracket 54. In this case, if a spacer is provided, itcould engage the upper end 61 of the bracket 54.

As yet another option, an interior side of the housing 14 may haveseparately attached or integrally formed hangers or slots to hold thecircuit board 32 in a position spaced away from the solenoid assembly20.

Referring to FIGS. 15-16 and 20-21, the housing 14 also is sized andshaped so that the entire housing 14 can be rotated for threadedattachment to irrigation equipment of various sizes without impactingstructure on the irrigation equipment. To accomplish this, the housing14 has one wall 120 generally extending around the coil 16 and generallycorresponding to the curvature of the coil 16 with its center ofcurvature being at axis L. The wall 120 includes one flat mid section122 extending around the bracket 54.

The housing 14 also has a radially expanded portion 124 for extendingaround the control circuitry 18. The expanded portion 124 includes acurved outer wall 126 extending over the control circuitry 18 andspecifically facing the circuit board 32. The outer wall 126 isconnected to the wall 120 by connecting walls 127. Since the outer wall126 is the part of the housing 14 that extends radially outward thefarthest, the outer wall 126 has a radius selected so that the outerwall avoids contact with structure on irrigation equipment while thehousing 14 is being attached to the irrigation equipment. For example,the outer wall 126 may have a radius R of approximately 1.07 inches orless so that in addition to the sprinkler rotor assembly 12, theintegrated control device 10 may be threaded onto a Rain Bird irrigationvalve 128 where the distance D from the center of the solenoid port 130on the valve to an edge 132 of a handle 134 on the valve is only 1.09inches as shown on FIG. 16. It is understood that this dimension may bevaried and can depend on the implementation. In some embodiments, thedistance D is designed to be less than 2 inches, in other embodiments,less than 1.5 inches, in other embodiments, less than 1.1 inches and inother embodiments, less than 1.0 inches. In the illustrated form, theouter wall 126 has a substantially constant radius although this neednot always be the case. Also, the outer wall 126 does not necessarilyhave its center of curvature at axis L of the coil 16.

Since the expanded portion 124 extends radially farther than theremainder of the housing 14, the device 10 rotates about axis Leccentrically like a cam while the integrated control device 10 isthreaded to the irrigation equipment 12 or 128.

Referring to FIGS. 15 and 17-18, with the maximum radius of the outerwall 126 being one of the key design limitations of some embodiments andwith the radius set as above, the electronic components 34 are arrangedon the circuit board 32 for the circuit board 32 to fit in the spacebehind the outer wall 126. Thus, the circuit board 32 is sized so thatthe outer wall 126 can maintain its substantially constant radius. Theouter wall 126 extends adjacent opposite lateral edges 136 of thecircuit board 32 while forming a gap 138 with a varying width betweenthe outer wall 126 and the circuit board 32. The electronic components34 are disposed on the circuit board 32 in locations to provideclearance for the outer wall 126. Thus, the electronic components 34 aredisposed on both of two main opposite surfaces 140 and 142 of thecircuit board 32. Also, the largest electronic components 144, such ascapacitors, are disposed at the widest location W of the gap 138 betweenthe outer wall 126 and the circuit board 32. The relatively large surgeabsorber 145 is also placed along the widest part W of the gap. In thepresent form, the widest location W of the gap 128 is locatedapproximately at a lateral midpoint between the lateral edges 136 of thecircuit board 32.

Referring to FIGS. 17-18, front and rear elevational views of oneembodiment of the control circuitry of the integrated irrigation valvecontrol device of FIG. 10 are shown. In these illustrations, variouselectrical components are illustrated in their arrangement on thecircuit board 32 in order to provide minimal footprint control circuitry18. In the front view of FIG. 17, illustrated are the largest electricalcomponents 144 (i.e., capacitors) and the surge absorber 145. In oneembodiment, the capacitors are 50V electrolytic capacitors. Othercomponents not yet specifically mentioned include optocoupler 770positioned under the surge absorber 145, crystal 772 (used as anoscillator for device timing), two diodes 774 (e.g., 1000 v, 1 ampdiodes), and two resistors 776 (e.g., 1 W resistors). The rear view ofFIG. 18 additionally illustrates two MOSFETs 778 (e.g., 50V, 3 ampMOSFETs), diodes 780 and controller 322 (e.g., see controller 322 (e.g.,see controller 322 described in FIG. 19 below, and including one or moreelements 324, 340, 330, 332 and 342 in FIG. 19).

Referring to FIG. 19, a functional block diagram is shown of oneembodiment of the control circuitry 18 shown in FIGS. 17-18 for anintegrated valve control device 10. As described above, the integratedvalve control device 10 couples with and controls actuation of a valveportion of irrigation equipment and further couples with a multi-wireinterface, such as two-wire interface or control wire path 901, toreceive power as well as irrigation control instructions, parametersand/or other such communications. In the illustrated embodiment, theintegrated valve control device 10 includes the control circuitry 18 andthe solenoid assembly 20 (e.g., actuator 356) at least partially coveredby the housing 14. The valve portion (valve 320) is coupled to theactuator 356. The control circuitry 18 is formed on or coupled to thecircuit board 32.

The integrated valve control device 10 includes an interface 326, acurrent feedback 328, a filter 325, an attenuator 336, an energy reserve352, driver circuits 354, actuator 356 (e.g., the solenoid assembly 20),an irrigation valve 320 and a demodulator 360. In the illustratedembodiment, the demodulator 360 includes a controller 322, one or morememory 324, an Analog to Digital conversion unit 330, a zero-crossdetector 332, one or more timers 340 (such as crystal-based clocks), anda device ID comparator 342. Under control of the controller 322, thevalve control device 10 can at least activate and deactivate irrigationby controlling water flow through the valve 320. The components of thevalve control device can be coupled through one or more directconnections, busses and/or other relevant coupling. The energy reserve352 and/or other back up power provides power to allow the valve controldevice 10 to turn on/off irrigation or initiate/terminate irrigationaccording to locally stored irrigation scheduling should power over thetwo-wire interface be interrupted. Power from the two-wire interfacecan, in some instances, be used to store power in the energy reserve352. While one energy reserve 352 is illustrated, it is understood thatthe energy reserve 352 may comprise multiple energy reserves. The energyreserve 352 may include one or both of a battery and capacitor. Inpreferred form, the one or more energy reserves 352 rectifies anincoming sinusoidal alternating power signal and includes one or morecapacitors 144 that are charged by power received from the two wireinterface and discharged using the driver circuits 354 to providesbursts of energy to open and close the actuator 356, e.g., a latchingsolenoid/solenoid assembly 20, controlling the irrigation valve 320. Insome embodiments, the energy reserve 352 stores power to provide DCpower to the demodulator 360 and other components of the device 10. Theenergy storage 352 can provide power in the event of disruption of powerfrom the two wire interface. In FIG. 19, all components except the valve320 are at least partially covered by the housing 14.

The valve control device 10 can be implemented through hardware,software, firmware or a combination of hardware, software and firmware.In some implementations, one or more components of the valve controldevice 10 are implemented through a single microprocessor, integratedcircuit, microcontroller or other device. Additionally or alternatively,one or more of the components of the valve control device 10 can beintegrated with the controller 322. For example, some or all of thememory 324, the zero-cross detector 332, the conversion unit 330, thetimer 340, ID comparator 342, the driver circuits 354 and/or othercomponents could be implemented in whole or in part through thecontroller 322. The valve control device 10, can in someimplementations, include a demodulator 360 that comprises one or morecomponents in demodulating the received input signal, such as thecontroller 322, the memory 324, the conversion unit 330, the zero-crossdetector 332, the ID comparator 342 and/or one or more timers 340. Insome embodiments, many of the components of the valve control device 10are implemented through a microcontroller, such as one of the series ofPIC16F677, 687, 689 manufactured by Microchip Technology, Inc. ofChandler, Ariz. or other similar controller.

The controller 322 can be implemented through one or more processors,microprocessors, microcontrollers, state machines or other such relevantcontrollers or combinations of controllers that provide overallfunctionality, data processing, and control over the valve controldevice 10. The one or more memory 324 can store software programs,executables, data, irrigation control programming, scheduling, runtimeparameters, soil conditions and parameters, other relevant programs anddata, and instructions executable by a processor, machine or computer.The memory can be implemented through ROM, RAM, EEPROM, volatile diskdrives, flash memory, removable medium (e.g., floppy disc, hard disc,compact disc (CD), digital versatile disc (DVD), flash memory, and thelike), and substantially any other relevant memory or combinations ofmemory. Generically, the memory 324 may also be referred to as acomputer readable medium.

As introduced above, the controller and/or other components of the valvecontrol device 10 can be implemented by software stored in memory andexecuted on a microcontroller or processor, or otherwise stored andexecuted in firmware. Further, the controller and/or other componentscan be implemented through logic devices, hardware, firmware and/orcombinations thereof. Thus, the processing described herein may beperformed using substantially any relevant processor logic or logiccircuitry.

The modulated alternating signal is received at the interface 326 (e.g.,input control connection 40 and/or wires 36 and 38) from the two wireinterface. In one embodiment, the interface 326 is simply a physicalconnection point, connector or coupler for electrically and mechanicallycoupling the multi wire control path to the valve control device 10. Innormal operation, the received alternating signal passes through theoptional current feedback 328 and is filtered by the filter 325,attenuated by the attenuator 336, and converted by the conversion unit330. The attenuator 336 attenuates the signal generating a data signal(VDATAF) that is at a level that is more readily utilized by the valvecontrol device 10. For example, in some instances, the voltage isattenuated to a level that can be utilized in integrated circuits, suchas about 5V or less. Further in some embodiments, the conversion unit330 identifies or extracts an input signal reference voltage (VREFF) asa reference level and/or bias level in further processing the inputsignal.

In one embodiment, the zero-cross detector 332 monitors input 326 andinforms the controller 322 when a positive going voltage has crossedfrom negative to positive. The timer 340 indicates a desired delay afterthe zero crossing and the controller 322 uses the analog to digitalconversion unit 330 to measure the voltage level. In one embodiment, thecontroller 322 compares this measured voltage to a threshold voltagelevel set in the memory 324. This voltage level is used to determineclipped waveforms representing logic “0” or non-clipped waveformsrepresenting logic “1”.

Data bits encoded on the signal can further activate or awaken at leasta portion of the valve control device 10 from a dormant or sleep statethat significantly reduces power consumption. The timer 340, in someembodiments, is utilized in cooperation with the controller 322 toidentify data bits and/or synchronization based on one or more timethresholds, for example, time since a detection of a data bit. The timer340 can also further activate or awaken at least a portion of the valvecontrol device 10 from a dormant or sleep state that significantlyreduces power consumption.

The ID comparator 342 extracts data from the received bits to determinewhether the communication modulated on the input signal is directed tothe valve control device 10 and/or identifies parameters, instructionsand/or requests. The controller 322 can implement one or moreinstructions, such as activating or deactivating one or more fieldstations 130, adjust parameters and/or implement other operations.

In some cases it is desirable for valve control device 10 to providefeedback to the entity providing input signal (e.g., irrigationcontroller 902 or other irrigation control unit or controllerinterface). For example, it is common for the valve control devices toacknowledge that they received and executed commands and instructionsprovided by the irrigation controller 902. This feedback may occur bythe valve control device shunting the power line (at wires 36 and 38)through a resistor used to receive input signal, which provides currentfeedback to the irrigation control system. That is, the shunting orshorting of the power lines causes a current draw (voltage drop) at adesignated time that is detected by controller 902 or other devicecontaining a modulator. In the embodiment of FIG. 19, the optionalcurrent feedback 328 provides the shunting as directed by the controller322 during designated feedback or communication times. In oneembodiment, the current feedback 328 includes a switch (for example, anelectronic switch, such as a triac) and resistor (not shown), the switchselectively coupling the two wires of the two wire interface 901together through the resistor when directed by the controller 322. Anexample of one embodiment of a modulated waveform used to provide powerand communicate data as well as allow for current feedback is providedin application Ser. No. 12/505,401, filed Jul. 17, 2009, and entitled“DATA COMMUNICATION IN A MULTI-WIRE CONTROL SYSTEM,” which is assignedto Rain Bird Corporation, this application is incorporated herein byreference.

In FIG. 19, valve control device 10 is shown having energy reserve 352in communication with conversion unit 330 via attenuator 336, whichoperates under the control of controller 322. The controller 322 alsocontrols the driver circuits 354 to activate and deactivate irrigation.Energy reserve 352 is shown to provide power to actuator 356 controllingthe valve 320 via driver circuits 354. Energy reserve 352 is charged bythe alternating power signal received at the interface 326.

In an embodiment, the energy reserve 352 functions as a stored energysource or as a stored energy reserve providing power to the actuator356, for example, a latching solenoid (solenoid assembly 20) ornon-latching solenoid, to open and/or close an associated irrigationvalve (e.g., valve 320) to effect irrigation. The energy reserve may beimplemented using a device (e.g., a battery and/or capacitor (e.g.,capacitors 144)) capable of providing desired power to the actuator.

If desired, energy reserve unit 352 may be implemented using one or moreadditional energy reserves (i.e., in addition to energy reserve 352).Such additional energy reserves may be used to power actuator 356 asneeded or desired. An example of a technique for implementing thismultiple energy reserve aspect is disclosed in copending applicationSer. No. 12/341,764, filed Dec. 22, 2008, and entitled “LATCHINGSOLENOID ENERGY RESERVE,” which is assigned to Rain Bird Corporation,which is the assignee of the present disclosure, this application isincorporated herein by reference.

As noted above, actuator 356 is usually coupled to a suitable irrigationvalve, such as valve 320, which in turn is coupled to a water supplyline on one end and to one or more water delivery devices on the otherend.

Actuator 356 is typically implemented using a latching solenoid (e.g.,see the solenoid assembly of FIGS. 10-16) which requires a certainamount of energy to open and close. A feature of the latching solenoidis that it may be configured to control water flow to one or more waterdelivery devices. In one position (e.g., the open position), theactuator (e.g., latching solenoid) causes the valve to be in an openvalve position to allow water flow therethrough. In another position(e.g., the closed position), the actuator (e.g., latching solenoid)causes the valve to be in a closed valve position which prevents theflow of water therethrough. A latching solenoid generally has lowerpower demands as compared to a typical non-latching solenoid. Forinstance, a typical non-latching solenoid requires continual power tomaintain the open valve position, the removal of power putting the valvein the closed valve position. Latching solenoids, on the other hand,only require a power burst to open or close; no power is needed tomaintain the latching solenoid (and thus, the valve) in the open orclosed position.

Accordingly, capacitors are well suited energy storage devices useful toprovide the short burst of power needed to move the actuator 356. Forexample, in some embodiments, the energy reserve 352 includes acapacitor (e.g., capacitors 144) that is charged using the receivedalternating power signal. The capacitor is discharged to provide thecurrent burst needed to actuate the latching solenoid. Once discharged,the capacitor immediately draws power from the alternating power signalto recharge.

With the configuration as described, when the spacer 50 is present, thecoil 16, bobbin 42, and bracket 54 are assembled together and mounted onthe spacer 50. The coil wires 112 and 114 are then attached to thecontrol circuitry 18 at the connection points 118. The control circuitry18, spacer 50, and coil 16 are then placed into the housing 14 bysimultaneously mounting the coil 16 on the core tube 62, sliding thecircuit board 32 next to outer wall 126, and sliding the bracket 54against flat mid wall 122. The jam nut 70 is then tightened to the coretube to secure the solenoid assembly 20 to the housing 14, and theplunger or valve member 28 is placed into the aperture 26 and core tube62 as described above. The housing 14 is then filled with the pottingmaterial 52.

Alternatively without any spacer, the process is generally the sameexcept that the circuit board 32 should be held away from the solenoidassembly while the housing 14 is being filled with the potting material52 so that the potting material can be inserted between the controlcircuitry 18 or circuit board 32 and the solenoid assembly 20.

As yet another alternative structure, the spacer 50 may be integrallyformed with, or otherwise part of, bobbin 42. In one possibleembodiment, the spacer merely includes legs or pads extending laterallyfrom the flanges 46 and 48 of the bobbin 42 for engagement with thecircuit board 32 to hold the bobbin 42, and in turn the coil 16, acertain distance from the circuit board 32. In this case, the coil wires112 and 114 may have had leads to attach to the circuit board 32. Inother embodiments, such a spacer that is part of the bobbin may includeother frame members for increased rigidity, similar to spacer 50, aswell as the legs. In some embodiments, other structural devices servingfunctionality of the spacer may be used instead of or in addition to aspacer. Further, in some embodiments, the spacer includes multiplepieces or portions. For example, there may be structure on the inside ofthe housing 16 to which the circuit board 32 is fixed and additionalstructure on the inside of the housing 16 to which the coil 16 and/orbobbin 42, etc. are fixed. In some embodiments, the spacer (orcomponents functioning as a spacer) functions at least in part to securethe circuit board 32 in a spaced relationship relative to the coil 16.

While the invention herein disclosed has been described by means ofspecific embodiments, examples and applications thereof, numerousmodifications and variations could be made thereto by those skilled inthe art without departing from the scope of the invention set forth inthe claims.

What is claimed is:
 1. An irrigation control device comprising: a coilconfigured to develop an electromagnetic flux sufficient to causeactuation of irrigation equipment; control circuitry electricallycoupled to the coil and configured to receive, at input connections,modulated power signals from an external irrigation control unit of anirrigation control system via a control wire path coupled to the inputconnections, wherein the control circuitry is configured to derivecontrol signals from the modulated power signals received from thecontrol wire path and based on the control signals, output signaling tothe coil to control the electromagnetic flux at the coil; and a housingcovering at least a portion of the coil and at least a portion of thecontrol circuitry, the housing having: a wall portion including a flatmid-wall generally extending around a portion of the coil and a pair ofcurved walls extending from the flat mid-wall and generally extendingaround a portion of the coil and generally corresponding to a curvatureof the portion of the coil; a radially expanded portion including acurved wall positioned opposite the flat mid-wall and generallyextending around the control circuitry; and a pair of curved wallsextending from a respective one of the curved walls that extend from theflat mid-wall and connect the curved walls that extend from the flatmid-wall to the curved wall of the radially expanded portion, the curvedwalls that extend from the curve walls extending from the flat mid-wallgenerally extending around a portion of the coil and generally extendingaround a portion of the circuitry.
 2. The irrigation control device ofclaim 1 wherein the housing is an integrally formed one-piece housing.3. The irrigation control device of claim 1 wherein any electricalconnection between the coil and the control circuitry remains within thehousing.
 4. The irrigation control device of claim 1 wherein the controlcircuitry comprises a circuit board and electronics mounted on thecircuit board, and wherein the housing is sized to cover the entirecircuit board and the entire coil.
 5. The irrigation control device ofclaim 1 wherein the coil comprises a side and a total longitudinallength, and wherein the control circuitry extends along the side and hasa total longitudinal length no more than approximately twice thelongitudinal length of the coil.
 6. The irrigation control device ofclaim 1 further comprising a curable potting material disposed at leastbetween the control circuitry and the coil and within the housing. 7.The irrigation control device of claim 6 wherein the potting materialsufficiently fills the housing so that the control circuitry and thecoil remain substantially fixed to each other.
 8. The irrigation controldevice of claim 6 wherein the control circuitry includes a circuit boardand electronic components mounted on the circuit board, the devicefurther comprising a spacer arranged to maintain the circuit boardspaced from the coil, and wherein only the spacer and the pottingmaterial are placed directly between the control circuitry and the coil.9. The irrigation control device of claim 1, wherein the control wirepath further comprises at least one input control wire coupled to thecontrol circuitry and extending out of the housing for connection to anirrigation control system.
 10. The irrigation control device of claim 1wherein the control circuitry is configured to receive the modulatedpower control signals and derive the control signals therefrom, whereinthe control signals are addressed to and intended for use by the controlcircuitry.
 11. The irrigation control device of claim 10, wherein thecontrol circuitry is configured to receive the modulated power controlsignals and derive the control signals therefrom, wherein the modulatedpower control signals contain other control signals not intended for useby the control circuitry, wherein the control circuitry is notresponsive to the other control signals.
 12. The irrigation controldevice of claim 1, wherein the control circuitry is one of a pluralityof other control circuits of other irrigation control devices alsoconfigured to be coupled to the control wire path.
 13. The irrigationcontrol device of claim 1, wherein the external irrigation control unitof the irrigation control system is directly coupled to a plurality ofother control circuits of other irrigation devices via the control wirepath.
 14. The irrigation control device of claim 1, wherein the housingis directly coupled to a valve assembly to be actuated by theelectromagnetic flux of the coil.
 15. The irrigation control device ofclaim 1 wherein the modulated power signals are modulated with data, andwherein the control circuitry is configured to derive the data from themodulated power signals, the data corresponding to the control signals,and based on the control signals, output the signaling to the coil tocontrol the electromagnetic flux at the coil.
 16. The irrigation controldevice of claim 1, wherein at least a portion of the coil is positionedin the expanded portion of the housing and is electrically connected tothe control circuitry in the expanded portion of the housing.
 17. Theirrigation control device of claim 1, wherein the curved walls extendingfrom the flat mid-wall extend in a divergent orientation relative toeach other thereby expanding the housing, and wherein the curved wallsextending from the respective ones of the pair of curved walls towardthe curved wall of the radially expanded portion extend in a divergentorientation relative to each other thereby further expanding thehousing.
 18. A method of making an irrigation control device comprising:holding a solenoid assembly with a coil near to control circuitry forcontrolling an electromagnetic flux at the coil, the control circuitryhaving input connections adapted to be coupled to an external irrigationcontrol unit of an irrigation control system via a control wire path tobe coupled to the input connections; electrically connecting the coil tothe control circuitry; placing the solenoid assembly and controlcircuitry into a housing, the housing having: a wall portion including aflat mid-wall generally extending around a portion of the coil and apair of curved walls extending from the flat mid-wall and generallyextending around a portion of the coil and generally corresponding to acurvature of the portion of the coil; a radially expanded portionincluding a curved wall positioned opposite the flat mid-wall andgenerally extending around the control circuitry; and a pair of curvedwalls extending from a respective one of the curved walls that extendfrom the flat mid-wall and connect the curved walls that extend from theflat mid-wall to the curved wall of the radially expanded portion, thecurved walls that extend from the curve walls extending from the flatmid-wall generally extending around a portion of the coil and generallyextending around a portion of the circuitry; securing the solenoidassembly to the housing so that the solenoid assembly can be actuated toreciprocate a valve member through an aperture in the housing toselectively engage a valve seat; and fixing the control circuitry andcoil within the housing; wherein the control circuitry is configured toreceive, at the input connections, modulated power signals from theexternal irrigation control unit via the control wire path coupled tothe input connections, and wherein the control circuitry is configuredto derive control signals from the modulated power signals and based onthe control signals, output signaling to the coil to control theelectromagnetic flux at the coil.
 19. The method of claim 18 wherein thehousing is a one-piece housing.
 20. The method of claim 18 wherein thehousing is a one-piece housing.
 21. The method of claim 18 wherein thevalve seat is secured to, and movable with, the housing.
 22. The methodof claim 18, wherein the housing is directly coupled to a valve assemblyto be actuated by the electromagnetic flux of the coil.
 23. The methodof claim 18 wherein the fixing of the control circuitry and coil withinthe housing comprises at least partially filling the housing with acurable material.
 24. The method of claim 18 further comprising placingthe control circuitry along a side of the coil so that the longitudinallengths of the coil and the control circuitry overlap.
 25. The method ofclaim 18, wherein at least a portion of the coil is positioned in theexpanded portion of the housing and is electrically connected to thecontrol circuitry in the expanded portion of the housing.
 26. The methodof claim 18, wherein the curved walls extending from the flat mid-wallextend in a divergent orientation relative to each other therebyexpanding the housing, and wherein the curved walls extending from therespective ones of the pair of curved walls toward the curved wall ofthe radially expanded portion extend in a divergent orientation relativeto each other thereby further expanding the housing.